Fundamental Research Of Efficient ECM On Complex Abnormity Channels

The parts which contain abnormity channels structure widely exist in the airspace engine, automobile, ship spare parts and airborne equipment. It is hard to process for most traditional processing methods due to its particularity structure. Because electrochemical machining technology has high machining efficiency, no tool wear and no cutting force, it has a good application prospect in abnormity channel parts processing. However, the affecting factors of the electrochemical machining process is too much, preparation period is long and improving the machining accuracy is difficult, how high quality and effective play to the advantages of electrochemical machining is the necessary research content to engineering application of electrochemical machining technology.In this paper, abnormity channels are as the research object. The different electrochemical machining process program is formulated according to different structure characteristics of abnormity channel parts. Electrochemical machining process design is carried out respectively for each type of abnormity channel, and the main research content includes the following several aspects:1、The electrochemical machining program designing of complex abnormity channels. The characteristics and processing difficulty of three kinds of abnormity channels parts are analyzed for typical abnormity channels parts; The Electrochemical machining process design for abnormity channels of each type is carried out respectively on basis of the analysis of the electrochemical machining accuracy and stability, and several key problems are summarized in electrochemical machining of abnormity channels.2、Based on the one-dimensional abnormity channel parts, the fixed cathode electrochemical machining experiment is carried out. Cathodes and special fixture are designed according to the characteristics structure of typical one-dimensional abnormity channel; the structure of cathode processing parts and insulation parts are optimized basing on the electric field and flow field analysis. Using optimized the cathode structure and on basis of a reasonable power parameter and fixed cathode taper, the experiment is carried out. The channel which meets machining accuracy is obtained, and the machining process is stability.3、Based on the three-dimensional abnormity channel parts, vibration feeding electrochemical machining experimental is carried out. To solve the problem of difficult to detect the electrolyte flow state in sealing device and long to fix fixture, pressure, velocity of electrolyte in sealing device are analyzed on basis of ANSYS FLUENT and the optimal lateral flow of electrolyte solution is obtained; The pressure parameters of imports and exports are optimized by analyzing the influence of the import pressure, export pressure and the feeding depth to the velocity distribution, pressure distribution within the machining gap; Influences of vibration feeding and cathode insulating are study with optimized electrolyte parameters.The above research work is an effective exploration to the electrochemical machining process design for complex abnormity channel parts and a systematic research to the typical abnormity of the channel, and some of which has been reasoned by small batch production. The study above is of great significance to solve manufacturing problem of complex abnormity channel structure parts.